CYLINDER HEAD SEALING SYSTEM AND METHOD

Abstract: A thermally conductive sealing system for the cylinder head joint (11) of an internal combustion engine (10) is disclosed comprising a spacer plate (24) clamped in direct contact between the cylinder head (12) and the cylinder block (14) and a plurality of discrete fluid gaskets (67, 70) disposed across the spacer plate (24) and clamped between the cylinder head (12) and cylinder block (14). The flange (22) of a cylinder liner (18) is received in a bore (26) of the spacer plate (24) and a combustion gas seal or "fire ring" (32) is clamped in the bore (26) between the cylinder head (12) and the cylinder liner flange (22). The combustion gas seal (32) includes a malleable sealing ring (42) for sealing between the cylinder head (12) and the cylinder liner (18) and a hardened backing ring (44) for supporting the sealing ring (42). The plurality of discrete fluid gaskets (67, 70) includes a removable lifter compartment gasket (70) including sealing elements (78, 80) attached across a substrate (71) and a plurality of coolant ferrules (67) for sealing across coolant ports (60, 62) and around cylinder head bolts (16).

Description: Description CYLINDER HEAD SEALING SYSTEM AND METHOD Technical Field This invention relates generally to a thermal stop cylinder head joint and sealing system that limits thermally induced loads from the cylinder head to the cylinder block or liner and, more particularly, to head gaskets for sealing receipt between a cylinder head and a cylinder block or liner of an internal combustion engine. Background of the Invention The cylinder head joint is a critical sealing joint in an internal combustion engine, particularly in high compression diesel engines. In addition to the typical sealing problems encountered at the cylinder head joint, such as preventing blowout of the combustion gas seal or wire ring while maintaining a coolant and/or oil tight head seal, diesel engines that employ flanged cylinder liners further complicate sealing of the cylinder head joint. For example, to avoid high unit loadings and associated crack initiation where the flange of the cylinder liner engages the engine block, a spacer plate or plates are provided in the cylinder head joint between the cylinder head and block. The spacer plates provide clearance for the flange of the cylinder liner to be mounted on the cylinder block in the cylinder head joint, rather than in a counter bore of the cylinder block, to reduce crack initiation in the cylinder block. Additionally, the spacer plates distribute mechanically induced cylinder head loads into the cylinder block without concentrating the loads on any one part of the cylinder block; i.e., the liner flange to cylinder block interface. Typically, the spacer plates are constructed of a thermally conductive material such as aluminum to distribute thermally induced cylinder head loads and reduce high thermal unit loading of the cylinder block. Presently, diesel engines employing flanged cylinder liners and spacer plates at the cylinder head joint have required gaskets clamped both between the cylinder block and spacer plate and between the spacer plate and cylinder head. These gaskets are shaped similar to the spacer plate and, for combination head gaskets with integral combustion gas seals, seal combustion gasses within the cylinder liner and both coolant and/or oil between the cylinder block and head. Although these gaskets adequately seal across the cylinder head joint, they nevertheless can be subject to leakage due to thermal loading during engine transients. Further, due to varying tolerances of the gaskets, the loading across the cylinder head joint can vary. As a result of these and other sealing difficulties, various gaskets have been developed in an attempt to improve sealing of the cylinder head joint. For example, U.S. Patent No. 5,125,551 to Slee discloses a combination cylinder head gasket and combustion gas seal which includes heat conductive elements between integral metal fire rings in an attempt to reduce thermal loading of the gasket. However, the cylinder head gasket disclosed in U.S. Patent No. 5,125,551 adds complexity and cost while still being susceptible to failure due to non-uniform heating during engine operation. As another example, the combination cylinder head gasket and combustion gas seal shown in U.S. Patent No. 5,125,375 to Vuk is adapted for use with a specially machined cylinder liner in an attempt to resist blowout of the integral combustion gas seal. The flange of the cylinder liner is machined frustoconical and cooperates with the cylinder head to produce a wedging action that resists radial expansion of the combustion gas seal when clamped between the cylinder head and liner. Aside from the machining difficulty involved in creating the frustoconical contour, the gasket disclosed in U.S. Patent No. 5,125,375 relies on a preset clearance between the cylinder flange and cylinder head to provide the necessary wedging action with the frustoconical contour. Should the cylinder head be improperly assembled or should the preset clearance become insufficient due to creep of the combustion gas seal, the gasket can be subject to blowout. A cylinder head gasket that combines a flexible sealing element with a metal gasket body to prevent detachment of the sealing element from the gasket body is shown in U.S. Patent No. 5,033,189 to Desverchere et al. Flexible sealing elements on either side of the metal gasket body are joined together through slots in the metal gasket body to reduce the risk of the sealing elements becoming detached therefrom. One disadvantage of this construction is that the flexible sealing element is formed integral with the metal gasket body, thus requiring the entire gasket body to be discarded should a portion of the flexible sealing element fail . What is needed is an improved gasket and gasket sealing system for, use in the cylinder head joint of an internal combustion engine that overcomes the aforementioned deficiencies of the gaskets disclosed in U.S. Patent Nos. 5,125,375, 5,033,189 and 5,125,551. Such a gasket sealing system should be compatible with diesel engines employing flanged cylinder liners and spacer plates at the cylinder head joint. Ideally, such a gasket sealing system should be inexpensive to manufacture and easily installed and, together with the spacer plate, should reduce thermal loading from the cylinder head to the combustion gas seal and cylinder block or liner. Summary of the Invention According to one embodiment of the present invention, a sealing system for a cylinder head joint of an internal combustion engine is disclosed comprising a spacer plate having a top mounting surface and a bottom mounting surface, the spacer plate including a plurality of engine fluid through holes for communicating engine fluids thereacross, means for clamping the spacer plate between the cylinder head and the cylinder block with the top mounting surface contacting the cylinder head mounting surface and the bottom mounting surface contacting the cylinder block mounting surface, and a first plurality of discrete engine fluid gaskets received in the plurality of engine fluid through holes clamped between the cylinder block and the cylinder head, the first plurality of discrete engine fluid gaskets sealing engine fluids within the plurality of engine fluid through holes. According to another embodiment of the present invention, a replaceable gasket is disclosed comprising a rigid substrate including an upper sealing surface, a lower sealing surface and a plurality of connecting holes extending between the upper sealing surface and the lower'sealing surface, the rigid substrate having a shape corresponding to the predetermined shape of the through hole of the spacer plate and being sized for receipt in the through hole, and a seal including an upper sealing element received against the upper sealing surface and adapted for sealing receipt between the upper sealing surface and the cylinder head, a lower sealing element received against the lower sealing surface and adapted for sealing receipt between the lower sealing surface and the cylinder block, and a plurality of connecting elements received through the plurality of connecting holes and interconnecting the upper sealing element with the lower sealing element. According to yet another embodiment of the present invention, a method for sealing a cylinder head joint of an internal combustion engine is disclosed comprising the steps of obtaining a spacer plate having a top mounting surface and a bottom mounting surface, the spacer plate including a plurality of engine fluid through holes for communicating engine fluids thereacross, placing the spacer plate on the cylinder block with the bottom mounting surface contacting the cylinder block mounting surface, obtaining a first plurality of engine fluid gaskets corresponding to the plurality of engine fluid through holes, placing the first plurality of engine fluid gaskets in the plurality of engine fluid through holes, placing the cylinder head on the spacer plate with the cylinder head mounting surface contacting the top mounting surface, and simultaneously clamping the spacer plate and the first plurality of engine fluid gaskets between the cylinder head and the cylinder block. According to still another embodiment of the present invention, a combustion gas seal is disclosed comprising a malleable sealing ring disposed between a cylinder head and a cylinder block or liner of an internal combustion engine. The malleable sealing ring is crushable between the cylinder head and the cylinder block or liner to form a seal when clamped therebetween. A backing ring is disposed adjacent to and radially outward of the malleable sealing ring for supporting the malleable sealing ring against deformation during operation of the engine. According to still yet another embodiment of the present invention, an improvement in a cylinder head joint of an internal combustion engine is disclosed, the cylinder head joint including a combustion gas seal and a spacer plate, the spacer plate being clamped at a predetermined clamp load between a cylinder head and a cylinder block, the cylinder block including a cylinder liner having a flanged portion extending upwardly from the cylinder block through a bore of the spacer plate, the improvement comprising the spacer plate being clamped in direct contact between the cylinder head and the cylinder block and the combustion gas seal being clamped in the bore of the spacer plate in sealing contact between the flanged portion of the cylinder liner and the cylinder head. According to yet another embodiment of the present invention, a method for sealing a cylinder head joint of an internal combustion engine is disclosed comprising the steps of obtaining a spacer plate having a top mounting surface and a bottom mounting surface, the spacer plate including at least one cylinder liner through hole for receiving a cylinder liner therein, placing the spacer plate on the cylinder block with the bottom mounting surface contacting the cylinder block mounting surface and with the cylinder liner received in the at least one cylinder liner through hole, placing a combustion gas seal in the cylinder liner through hole onto the cylinder liner, placing the cylinder head on the spacer plate and the combustion gas seal, and clamping the spacer plate between the cylinder head and the cylinder block and the combustion gas seal between the cylinder head and the cylinder liner. One object of the present invention is to provide an improved gasket sealing system for the cylinder head joint of an internal combustion engine. Another object of the present invention is to provide an improved combustion gas seal or "fire ring" for use in the cylinder head joint of an internal combustion engine. Yet another object of the present invention is to provide an improved head gasket for sealing engine fluids such as coolant and\or oil communicated between the cylinder head and cylinder block. Still yet another object of the present invention is to provide an improved thermal joint between the cylinder head and cylinder block of an internal combustion engine that reduces thermal unit loading of the cylinder block. Yet another object of the present invention is to provide an improved head joint that reduces thermal loading of the combustion gas seal during engine transients. These and other related objects and advantages of the present invention will become apparent from the following drawings and written description. Brief Description of the Drawings Fig. 1 is a partial side cross-sectional view depicting a cylinder head joint of a diesel engine according to one embodiment of the present invention. Fig. 2 is an exploded cross-sectional view of the cylinder head joint of Fig. 1. Fig. 3 is a top plan view of a combustion gas seal or "fire ring" of the cylinder head joint of Fig. 1. Fig. 4 is a partial side cross-sectional view of the combustion gas seal of Fig. 3. Fig. 5 is a partial side cross-sectional view of an alternate combustion gas seal for use in the cylinder head joint of Fig. 1. Fig. 6 is a top plan view of a spacer plate having coolant ferrules for sealing coolant ports and cylinder head bolts and a replaceable gasket for sealing a lifter compartment of the cylinder head joint of Fig. 1. Fig. 7 is a side cross-sectional view of the coolant ferrule taken along line 7-7 of Fig. 6. Fig. 8 is a top plan view of the replaceable lifter compartment gasket of Fig. 6. Fig. 9 is a partial side cross-sectional view of the replaceable lifter compartment gasket taken along line 9-9 of Fig. 8. Description of the Preferred Embodiment Referring to Fig. 1, a diesel engine 10 is shown incorporating a cylinder head joint 11 according to one embodiment of the present invention. Engine 10 includes a cylinder head 12 mounted clamped on a cylinder block 14 via a plurality of cylinder head bolts 16. A cylinder liner 18 is slidably mounted within a bore 20 of cylinder block 14. Cylinder liner 18 defines a cylinder bore 19 and includes a flanged portion 22 extending upwardly from cylinder block 14 into the cylinder head joint. A spacer plate 24 is mounted between cylinder head 12 and cylinder block 14 and includes a cylinder liner through hole 26 for receiving flanged portion 22 of cylinder liner 18 therein. Spacer plate 24 distributes both mechanical and thermally induced cylinder head loads from the cylinder head into the cylinder block without concentrating the cylinder head loads at any one portion of the cylinder block. Prior to the present invention, a head gasket in the form of a gasket plate was mounted clamped between the spacer plate 24 and engine block 14 to seal across engine fluid passageways such as the seal lifter compartment and coolant ports. Similarly, a head gasket incorporating a combustion gas seal or "fire ring" was mounted clamped between the cylinder head and spacer plate. The present invention eliminates the need for head gaskets between the spacer plate and cylinder head and between the spacer plate and cylinder block and relies instead on discrete gaskets and seals at the various specific fluid interfaces across the cylinder head joint. For example, referring now to Fig. 2, the cylinder head joint 11 of the present invention is shown in greater detail. In Fig. 2, the top and bottom mounting surfaces 28 and 30, respectively, of spacer plate 24 are mounted contacting corresponding mounting surfaces of cylinder head 12 and cylinder block 14. By directly contacting cylinder head 12 onto spacer plate 24 and directly contacting spacer plate 24 onto cylinder block 14, any insulative gaps present across the cylinder head joint are eliminated so that heat is conducted evenly and directly across the cylinder head joint. Further, during transient operation of the engine, the solid abutment of the spacer plate between the cylinder head and cylinder block resists thermal loading of the combustion gas seal and reduces motion of the cylinder head relative to the combustion gas seal and cylinder block. As a result, distortion and wearing of the combustion gas seal is minimized to provide a more stable cylinder head joint. Preferably, spacer plate 24 is constructed of a conductive material such as aluminum so that the heat loading conducted from cylinder head 12 is substantially evenly distributed through spacer plate 24 prior to being conducted into cylinder block 14. As such, severe temperature gradients from the cylinder head are reduced across spacer plate 24 to reduce thermal loading of cylinder block 14. Additionally, the thermal growth characteristics of an aluminum spacer plate relative to those of the cylinder head, block and liner ensure a tight cylinder head joint at engine operating temperatures. To facilitate direct contact between the cylinder head, spacer plate and cylinder block, discrete gaskets are provided situated across the spacer plate between the cylinder head and cylinder block or liner to selectively seal the various fluid interfaces across the cylinder head joint. For example, rather than providing an integral head gasket and combustion gas seal across the cylinder head clamped between the cylinder head and spacer plate to seal both combustion gasses and engine oil and/or coolants, a discrete combustion gas seal or fire ring 32 is provided clamped between flanged portion 22 of cylinder liner 18 and cylinder head 12 to seal only combustion gasses. Fire ring 32 is received in an annular slot 34 machined in liner 18 so that a predetermined clamp load is applied across ring 32. The clamp load applied to fire ring 32 is set by the predetermined clearance in slot 34 between the cylinder liner and the cylinder head, rather than solely by the cylinder head bolt load, when the cylinder head is clamped in place against spacer plate 24 onto block 14. As a result, the clamp load applied to fire ring 32 is selectable independent of the clamp load applied by the cylinder head bolts across the spacer plate. Also, by eliminating the gaskets between the cylinder head and spacer plate and between the spacer plate and cylinder block, the tolerance stack and associated load variation across the combustion gas seal is reduced to permit increased nominal loading of the combustion gas seal . Similarly, torque relaxation of the cylinder head bolts is reduced since the overall assembly of the cylinder head joint is less susceptible to dimensional change due to creep of the various gaskets and seals. Referring now to Figs. 3 and 4, combustion gas seal or fire ring 32 is shown in greater detail. Fire ring 32 includes an annular sleeve 36 having an upper sealing member 38 adapted for sealing contact against cylinder head 12 and a lower sealing member 40 adapted for sealing contact against cylinder liner 18. A malleable sealing ring 42 is disposed in annular sleeve 36 between upper sealing member 38 and lower sealing member 40. Malleable sealing ring 42 is crushable within annular sleeve 36 to provide a conforming seal between the cylinder head and the cylinder liner when clamped in place. To prevent annular sleeve 36 and sealing ring 42 from blowing out under high combustion gas pressures, a backing ring 44 is disposed in annular sleeve 36 radially outward of malleable sealing ring 42. Backing ring 44 is constructed of a material having sufficient strength to support sealing ring 42 against deformation at the high combustion gas pressures. For example, at gas pressures in excess of 13,790 kPa (2000 psi) and including a factor of safety as known in the art, backing ring 44 is constructed of a material having an ultimate tensile strength in the range of about 482,633 kPa (70,000 psi) to about 896,318 kPa (130,000 psi) and, preferably, of about 737,739 kPa (107,000 psi) for supporting the sealing ring against a design gas pressure of approximately 27,579 kPa (4000 psi) . Preferably, annular sleeve 36 is generally U-shaped in cross-section to wrap around malleable sealing ring 42 and restrain sealing ring 42 in place. Further, to facilitate assembly of fire ring 32 in annular slot 34 centered about cylinder bore 19, means for centering are provided in the form of a plurality of peripherally spaced tabs 46 attached to annular sleeve 36. Tabs 46 cooperate with flanged portion 22 of cylinder liner 18 to locate gasket 36 centered both within annular slot 34 and about cylinder bore 19 (Fig. 2) . In one specific embodiment, annular sleeve 36 and sealing ring 42 are constructed of stainless steel, wherein sealing ring 42 is fully annealed having a hardness in the range of 78-88 on a Rockwell 15-T scale. In this specific embodiment, backing ring 44 is similarly constructed of stainless steel having a hardness of at least 20 on a Rockwell C scale to provide the necessary strength for supporting the fully annealed sealing ring. Fire ring 32 is indexed as well relative to the cylinder bore and liner to prevent rotation of the gasket during assembly. For example, in Fig. 2, a plurality of peripherally spaced slots 48 are provided in spacer plate 24 corresponding to tabs 46 so that tabs 46 are received in slots 48 when assembled in place in annular slot 34. Other discrete combustion gas seals or fire rings are contemplated that include a malleable sealing ring and backing ring for sealing receipt between cylinder head 12 and cylinder liner 18. For example, referring now to Fig. 5, an alternate combustion gas seal or fire ring 50 is depicted employing a two-piece construction. A malleable sealing ring 52 similar to sealing ring 42 seals between the cylinder head and liner. A separate backing ring 54 prevents blowout of sealing ring 52 under high combustion pressures. The backing ring 54 further incorporates means for centering and indexing sealing ring 52 about cylinder bore 19 in the form of integral downwardly extending tabs 56. Similar to the discrete combustion gas seal 32, other discrete gaskets and/or seals are provided in lieu of a head gasket to seal various coolant and oil fluid interfaces across the spacer plate. For example, rather than providing head gaskets between the cylinder head and spacer plate and/or between the spacer plate and cylinder block, discrete gaskets are received across the spacer plate in sealing contact between the cylinder head and cylinder block. Referring now to Fig. 6, spacer plate 24 is shown in greater detail including a variety of discrete engine fluid seals contained by the spacer plate. The spacer plate 24 includes a plurality of coolant ports 60 and 62 disposed about cylinder liner through hole 26 for communicating engine coolant between the cylinder head 12 and cylinder block 14. Disposed between coolant ports 60 and 62 are cylinder head bolt through holes 64 for receiving cylinder head bolts 16 therethrough. Adjacent to the liner flange through hole 26 is an irregular-shaped crankcase through hole 66 which provides clearance for a valve lifter and communicates with a valve lifter compartment. A plurality of various sized coolant ferrules 67 are disposed in coolant ports 60 and 62 for sealing engine coolant between the cylinder head and the cylinder block. The present invention further utilizes coolant ferrules 67 to seal about cylinder head bolts 16, thereby preventing any coolant leakage from corroding the cylinder head bolts and preventing any combustion gas leakage from relaxing the cylinder head bolt material. Referring now to Fig. 7, coolant ferrules 67 are generally cylindrical in shape and include a cylindrical metal core 68 encased in a rubber or plastic sheath 69. Sheath 69 extends beyond core 68 so that when the ferrule is clamped between the cylinder head and block, only the rubber or plastic sheath 69 deforms to provide a liquid-tight seal supported between the cylinder head and the cylinder block by the metal core 68. Because the present invention eliminates gasket plates between the spacer plate and cylinder block, an additional seal 70 is required for sealing across spacer plate 24 about the lifter compartment. Gasket 70 is irregularly shaped to conform to the shape of the lifter compartment through hole 66. Referring now to Figs. 8 and 9, gasket 70 includes a rigid substrate 71 having an upper sealing surface 72, a lower sealing surface 74, and a plurality of connecting holes 76 extending between upper sealing surface 72 and lower sealing surface 74. A flexible sealing element 77 is received across the rigid substrate and includes an upper sealing element 78 for sealing between upper sealing surface 72 and cylinder head 12 and a lower sealing element 80 for sealing between lower sealing surface 74 and cylinder block 14. Sealing elements 78 and 80 are interconnected by a plurality of connecting elements 81 received through the connecting holes 76. Connecting elements 81 restrain the sealing elements 78 and 80 across substrate 71 to prevent the sealing elements 78 and 80 from detaching therefrom. Sealing elements 78 and 80 are preferably sized larger than the connecting elements 81 so that, although being attached to one another, sealing elements 78 and 80 deform independently when clamped to seal separate from one another. For example, referring to FIG. 9, the cross-sectional width of sealing elements 78 and 80 is depicted larger than the cross-sectional diameter of connecting element 81. Preferably, the cross-sectional width of each of sealing elements 78 and 80 is at least twice as great as the cross-sectional diameter of connecting element 81 to provide sufficient sealing area for surfaces 72 and 74 to support sealing elements 78 and 80 independent of one another. Additionally, the height of sealing elements 78 and 80 from sealing surfaces 72 and 74, respectively, is depicted shorter than the length of connecting element 81 between sealing surfaces 72 and 74. Preferably, the length of connecting element 81 between sealing surfaces 72 and 74 is at least two times the height of each sealing element 78 and 80 from sealing surfaces 72 and 74 and, in the specific embodiment shown in FIG. 9, about two to three times the height of each sealing element 78 and 80 from sealing surfaces 72 and 74. Rigid substrate 71 includes a rectangularly shaped cross-sectional core portion 82 defining upper sealing surface 72 and lower sealing surface 74 and containing connecting holes 76 therebetween. Additionally, a backing portion 84 is provided to further support the sealing elements. The backing portion 84 extends above upper sealing surface 72 to define a shoulder 86 for restraining the upper sealing element 78 in place. Similarly, backing portion 84 extends below lower sealing surface 74 to define a shoulder 88 for restraining lower sealing element 80 in place. As such, the flexible sealing elements 78 and 80 are further restrained from being detached from the substrate during assembly. To further bolster shoulders 86 and 88, the backing portion 84 is generally T-shaped in cross-section and includes gussets 90 for reinforcing shoulders 86 and 88 across the T-shaped cross-section. Unlike prior art gasket plates which employ integral flexible sealing elements attached thereacross, gasket 70 is supported independent of spacer plate 24 by the rigid substrate 71 and, therefore, is easily replaceable. As such, refurbishment of gasket 70 does not require replacement of the spacer plate. Further, the gasket is easily constructed of molded plastic to facilitate incorporation of the various shoulders and gussets for added strength and rigidity. Gasket 70 includes locating pins 92 which are received in corresponding slots 94 of spacer plate 24 to restrain gasket 70 in place during assembly. In one specific embodiment, gasket 70 is shaped to provide clearance for cylinder head bolts 16, as shown in Fig. 6, and is molded to provide an integral fluid passageway 96 adapted for receiving a coolant ferrule 67 and communicating engine fluids similar to coolant ports 62. Preferably, substrate 71 is constructed of a rigid plastic and the sealing elements are constructed of a flexible elastomer. For example, in the preferred embodiment rigid substrate 71 is constructed either of polyethersulfone (PES) or an approximately 30% by weight glass-filled polymeric amide such as Nylon and the sealing elements are constructed either of a highly saturated nitrile rubber (HSN) or a fluorocarbon such as a vinylidene fluoride - hexafluoropropylene copolymer (Viton) . Industrial Applicability To assemble the cylinder head joint, spacer plate 24 is placed on cylinder block 14 with bottom mounting surface 30 contacting a corresponding mounting surface of the cylinder block and with flanged portion 22 of cylinder liner 18 received in cylinder liner through hole 20. A plurality of appropriately sized coolant ferrules 67 corresponding to the plurality of coolant ports 60 and 62 of the spacer plate are placed one for one and contained in the plurality of coolant ports. A second plurality of appropriately sized coolant ferrules 67 corresponding to the plurality of cylinder bolt through holes 64 are placed one for one about cylinder head bolts 16 and contained in the plurality of cylinder head bolt through holes. Lifter compartment gasket 70 is placed in lifter compartment through hole 66 and oriented with tabs 92 received in corresponding slots 94 of the spacer plate. Combustion gas seal 32 is placed in slot 34 on the top surface of cylinder liner flange 34. The combustion gas seal is centered about cylinder bore 19 during assembly by locating tabs 46 over flanged portion 22. Combustion gas seal 32 is indexed in place by inserting tabs 46 into slots 48 of spacer plate 24. Tabs 46 cooperate with spacer plate 24 to maintain combustion gas seal 32 in place on cylinder liner 18 during assembly. Cylinder head 12 is clamped onto cylinder block 14 via cylinder head bolts 16 with the mounting surface of cylinder head 12 contacting top mounting surface 28 of spacer plate 24 and combustion gas seal 32. When clamped, cylinder head 12 and cylinder liner 18 define a predetermined assembly clearance therebetween in cylinder liner through hole 26. Spacer plate 24 is clamped at a first predetermined clamp load between cylinder head 12 and cylinder block 14, and combustion gas seal 32 is clamped in the predetermined assembly clearance at a second predetermined clamp load selectable independent of the first predetermined clamp load. For example, the cylinder head bolt load applied across the spacer plate during assembly can be selected sufficiently high to accommodate the differential thermal expansion across the cylinder head joint without loading the combustion gas seal at assembly. Similarly, the combustion gas seal load can be selected sufficiently high at assembly to maintain a tight gas seal at peak cylinder pressures without simultaneously loading the remaining fluid seals and cylinder head bolts.

Claims: Claims 1. A sealing system for a cylinder head joint (11) of an internal combustion engine (10) , the cylinder head joint (11) including a cylinder head (12) having a cylinder head mounting surface and a cylinder block (14) having a cylinder block mounting surface, the sealing system comprising: a spacer plate (24) having a top mounting surface (28) and a bottom mounting surface (30) , said spacer plate (24) including a plurality of engine fluid through holes (60,62,66) for communicating engine fluids thereacross; means for clamping said spacer plate (24) between the cylinder head (12) and the cylinder block (14) with said top mounting surface (28) contacting the cylinder head mounting surface and said bottom mounting surface (30) contacting the cylinder block mounting surface; and a first plurality of discrete engine fluid gaskets (67,70) received in said plurality of engine fluid through holes (60,62,66) clamped between the cylinder block (14) and the cylinder head (12) , said first plurality of discrete engine fluid gaskets (67,70) sealing engine fluids within said plurality of engine fluid through holes. 2. The sealing system of claim 1, and further comprising: a second plurality of discrete engine fluid gaskets (67) clamped between the cylinder block (14) and the cylinder head (12) ; wherein said means for clamping includes a plurality of cylinder head bolts (16) extending between the cylinder head (12) and the cylinder block (14) ; said spacer plate (24) includes a plurality of cylinder head bolt through holes (64) for receiving said plurality of cylinder head bolts (16) therethrough; and said second plurality of. engine fluid gaskets (67) are received about said plurality of cylinder head bolts (16) in said plurality of cylinder head bolt through holes (64) clamped between the cylinder block (14) and the cylinder head (12) . 3. The sealing system of claim 2, wherein: said plurality of engine fluid through holes (60,62,66) includes a crankcase through hole (66) adapted for receiving a reciprocating pushrod therethrough and a plurality of coolant ports (60,62) adapted for receiving engine coolant therethrough; said first plurality of engine fluid gaskets (67,70) includes a crankcase gasket (70) corresponding to said crankcase through hole (66) and a plurality of coolant ferrules (67) corresponding to said plurality of coolant ports (60,62) ; and said second plurality of engine fluid gaskets (67) includes a second plurality of coolant ferrules (67) corresponding to said plurality of cylinder head bolt through holes (64) . 4. The sealing system of claim 3, wherein said crankcase gasket (70) includes: a rigid substrate (71) including an upper sealing surface (72) , a lower sealing surface (74) and a plurality of connecting holes (76) extending between said upper sealing surface (72) and said lower sealing surface (74) ; and a seal (77) including an upper sealing element (78) received against said upper sealing surface (72) and adapted for sealing receipt between said upper sealing surface (72) and the cylinder head (12) , a lower sealing element (80) received against said lower sealing surface (74) and adapted for sealing receipt between said lower sealing surface (74) and the cylinder block (14) , and a plurality of connecting elements (81) received through said plurality of connecting holes (76) and interconnecting said upper sealing element (78) with said lower sealing element (80) . 5. The sealing system of claim 4, wherein said rigid substrate (71) includes: a core portion (82) defining said upper sealing surface (72) and said lower sealing surface (74) ; and a backing portion (84) attached to said core portion (82) , said backing portion (84) extending above said upper sealing surface (72) to define a first shoulder (86) for supporting said upper sealing element (78) and extending below said lower sealing surface (74) to define a second shoulder (88) adapted for supporting said lower sealing element (80) . 6. The sealing system of claim 5, wherein said backing portion (84) is generally T-shaped in cross-section and includes gussets (90) for reinforcing said first shoulder (86) and said second shoulder (88) . 7. A replaceable gasket (70) for sealing across a spacer plate (24) clamped between a cylinder head (12) and a cylinder block (14) of an internal combustion engine (10) , the spacer plate (24) including a through hole (66) having a predetermined shape for communicating a first engine fluid thereacross, the gasket (70) comprising: a rigid substrate (71) including an upper sealing surface (72) , a lower sealing surface (74) and a plurality of connecting holes (76) extending between said upper sealing surface (72) and said lower sealing surface (74) , said rigid substrate (71) having a shape corresponding to the predetermined shape of the through hole (66) of the spacer plate (24) and being sized for receipt in the through hole (66) ; and a seal (77) including an upper sealing element (78) received against said upper sealing surface (72) and adapted for sealing receipt between said upper sealing surface (72) and the cylinder head (12) , a lower sealing element (80) received against said lower sealing surface (74) and adapted for sealing receipt between said lower sealing surface (74) and the cylinder block (14) , and a plurality of connecting elements (81) received through said plurality of connecting holes (76) and interconnecting said upper sealing element (78) with said lower sealing element (80) . 8. The gasket (70) of claim 7, wherein said rigid substrate (71) includes a core portion (82) defining said upper sealing surface (72) and said lower sealing surface (74) and a backing portion (84) attached to said core portion (82) , said backing portion (84) extending above said upper sealing surface (72) to define a first shoulder (86) for supporting said upper sealing element (78) and extending below said lower sealing surface (74) to define a second shoulder (88) for supporting said lower sealing element (80) . 9. The gasket (70) of claim 8, wherein said upper sealing surface (72) is spaced from said lower sealing surface (74) so that said upper sealing element (78) deforms substantially independently of said lower sealing element (80) when clamped between the cylinder head (12) and the cylinder block (14) . 10. The gasket (70) of claim 8, wherein each of said plurality of connecting elements (81) have a first cross-sectional area and said upper sealing element (78) and said lower sealing surface (80) each have a second cross-sectional area greater than said first cross-sectional area so that said upper sealing element (78) deforms substantially independently of said lower sealing element (80) when clamped between the cylinder head (12) and the cylinder block (14) . 11. The gasket (70) of claim 10, wherein said substrate (71) includes an integral fluid passageway (96) for communicating a second engine fluid therethrough separate from said first engine fluid. 12. The gasket (70) of claim 11, wherein said backing portion (84) is generally T-shaped in cross-section and includes gussets (90) for reinforcing said first shoulder (86) and said second shoulder (88) . 13. The gasket (70) of claim 7, and further comprising locating tabs (92) adapted for locating said gasket (70) in corresponding locating slots (94) of the spacer plate (24) . 14. The gasket (70) of claim 7, wherein said rigid substrate (71) is molded from a rigid plastic. 15. The gasket (70) of claim 14, wherein said rigid plastic is constructed of an approximately 30% by weight glass filled polymeric amide. 16. The gasket (70) of claim 14, wherein said rigid plastic is constructed of a polyethersulfone. 17. The gasket (70) of claim 7, wherein said seal is molded from an elastomer. 18. The gasket (70) of claim 17, wherein said elastomer is constructed of a vinylidene fluoride - hexafluoropropylene copolymer. 19. The gasket (70) of claim 17, wherein said elastomer is constructed of a highly saturated nitrile rubber. 20. A method for sealing a cylinder head joint (11) of an internal combustion engine (10) , the cylinder head joint (11) including a cylinder head (12) having a cylinder head mounting surface and a cylinder block (14) having a cylinder block mounting surface, the method for sealing comprising the steps of: obtaining a spacer plate (24) having a top mounting surface (28) and a bottom mounting surface (30) , said spacer plate (24) including a plurality of engine fluid through holes (60,62,66) for communicating engine fluids thereacross; placing said spacer plate (24) on the cylinder block (14) with said bottom mounting surface (30) contacting the cylinder block mounting surface; obtaining a first plurality of engine fluid gaskets (67,70) corresponding to said plurality of engine fluid through holes (60,62,66) ; placing said first plurality of engine fluid gaskets (67,70) in said plurality of engine fluid through holes (60,62,66); placing the cylinder head (12) on said spacer plate (24) with the cylinder head mounting surface contacting said top mounting surface (28) ; and simultaneously clamping said spacer plate (24) and said first plurality of engine fluid gaskets (67,70) between the cylinder head (12) and the cylinder block (14) . 21. The method of claim 20, wherein the cylinder head joint (11) includes a plurality of cylinder head bolts (16) extending between the cylinder head (12) and the cylinder block (14) and said spacer plate (24) includes a plurality of cylinder head bolt through holes (64) for receiving said plurality of cylinder head bolts (16) therethrough, the method for sealing further comprising the steps of: obtaining a second plurality of engine fluid gaskets (67) corresponding to said plurality of cylinder head bolt through holes (64) ; placing said second plurality of engine fluid gaskets (67) in said plurality of cylinder head bolt through holes (64) ; and simultaneously clamping said spacer plate (24) , said first plurality of engine fluid gaskets (67,70) and said second plurality of engine fluid gaskets (67) between the cylinder head (12) and the cylinder block (14) . 22. The method of claim 20, wherein said plurality of engine fluid through holes (60,62,66) includes a crankcase through hole (66) and said first plurality of engine fluid gaskets (67,70) includes a replaceable crankcase gasket (70) , wherein the method for sealing includes the steps of: placing said replaceable crankcase gasket (70) in said crankcase through hole (66) ; and simultaneously clamping said spacer plate (24) and said replaceable crankcase gasket (70) between the cylinder head (12) and the cylinder block (14) . 23. A combustion gas seal (32) for sealing receipt about a cylinder bore (19) clamped between a cylinder head (12) and a cylinder block (14) or liner (18) of an internal combustion engine (10) , comprising: a malleable sealing ring (42) disposed between the cylinder head (12) and the cylinder block (14) or liner (18) ; said malleable sealing ring (42) being crushable between the cylinder head (12) and the cylinder block (14) or liner (18) to form a seal when clamped therebetween; and a backing ring (44) disposed adjacent to and radially outward of said malleable sealing ring (42) for supporting said malleable sealing ring (42) against deformation during operation of. the engine (10) . 24. The combustion gas seal (32) of claim 23, and further comprising: an annular sleeve (36) including an upper sealing member (38) adapted for sealing contact against the cylinder head (12) and a lower sealing member (40) adapted for sealing contact against the cylinder block (14) or liner (18) ; wherein said malleable sealing ring (42) is disposed in said annular sleeve (36) between said upper sealing member (38) and said lower sealing member (40) , said malleable sealing ring (42) being crushable within said annular sleeve (36) between the cylinder head (12) and the cylinder block (14) or liner (18) when clamped therebetween; and wherein said backing ring (44) is disposed in said annular sleeve (36) radially outward of said malleable sealing ring (42) . 25. The combustion gas seal (32) of claim 24, and further comprising means for centering (46) said combustion gas seal (32) about the cylinder bore (19) . 26. The combustion gas seal (32) of claim 25, wherein said annular sleeve (36) is generally U- shaped in cross-section. 27. The combustion gas seal (32) of claim 26, wherein said means for centering (46) includes a plurality of peripherally spaced tabs (46) attached to said annular sleeve (36) and cooperative with the cylinder block (14) or cylinder liner (18) to locate said combustion gas seal (32) centered about the cylinder bore (19) . 28. The combustion gas seal (32) of claim 27, wherein said backing ring (44) is constructed from a material having an ultimate tensile strength greater than 482,633 kPa (70,000 psi) . 29. The combustion gas seal (32) of claim 28, wherein said backing ring (44) is constructed of steel having a minimum hardness of 20 on a Rockwell C scale. 30. The combustion gas seal (32) of claim 24, wherein said annular sleeve (36) is generally U- shaped in cross-section. 31. The combustion gas seal (32) of claim 23, wherein said backing ring (44) is constructed from a material having an ultimate tensile strength greater than 482,633 kPa (70,000 psi) . 32. The combustion gas seal (32) of claim 31, wherein said backing ring (44) is constructed of stainless steel having a minimum hardness of 20 on a Rockwell C scale. 33. In a cylinder head joint (11) of an internal combustion engine (10) , the cylinder head joint (11) including a combustion gas seal (32) and a spacer plate (24) , said spacer plate (24) being clamped at a predetermined clamp load between a cylinder head (12) and a cylinder block (14) , said cylinder block (14) including a cylinder liner (18) having a flanged portion (22) extending upwardly from said cylinder block (14) through a bore (26) of said spacer plate (24) , the improvement comprising said spacer plate (24) being clamped in direct contact between said cylinder head (12) and said cylinder block (14) and said combustion gas seal (32) being clamped in said bore (19) in sealing contact between said flanged portion (22) of said cylinder liner (18) and said cylinder head (12) . 34. The improvement of claim 33, wherein said cylinder head (12) and said flanged portion (22) of said cylinder liner (18) define a predetermined assembly clearance in said bore (26) for receiving said combustion gas seal (32) at a predetermined clamp load therein selectable independent of the predetermined clamp load across said spacer plate (24) . 35. The improvement of claim 34, wherein said combustion gas seal (32) includes: a malleable sealing ring (42) disposed in said bore (26) and adapted for sealing between said cylinder head (12) and said cylinder liner (18) ; and a hardened backing ring (44) disposed in said bore (26) adjacent to and radially outward of said malleable sealing ring (42) . 36. The improvement of claim 35, wherein said combustion gas seal (32) further includes: an annular sleeve (36) disposed about said malleable sealing ring (42) , said annular sleeve (36) including an upper sealing member (38) for sealing contact against said cylinder head (12) and a lower sealing member (40) for sealing contact against said cylinder liner (18) ; said malleable sealing ring (42) being crushable within said annular sleeve (36) between said cylinder head (12) and said cylinder liner (18) when clamped therebetween. 37. The improvement of claim 36, wherein said annular sleeve (36) is generally U-shaped in cross-section. 38. The combustion gas seal (32) of claim 37, wherein said backing ring (44) is constructed from a material having an ultimate tensile strength greater than 482,633 kPa (70,000 psi) . 39. The improvement of claim 38, wherein said hardened backing ring (44) is constructed of stainless steel having a minimum hardness of 20 on a Rockwell C scale. 40. The improvement of claim 33, and further comprising means for centering (46) combustion gas seal (32) about a cylinder bore (19) of said cylinder liner (18) . 41. The improvement of claim 40, wherein said means for centering (46) includes a plurality of peripherally spaced tabs (46) attached to said annular sleeve (36) and cooperative with said cylinder liner (18) to locate said combustion gas seal (32) centered about said cylinder bore (19) . 42. The improvement of claim 41, and further comprising means for circumferentially indexing (46,48) said combustion gas seal (32) about said cylinder bore (19) . 43. The improvement of claim 42, wherein said means for circumferentially indexing (46,48) includes a plurality of peripherally spaced slots (48) disposed in said spacer plate (24) adjacent to said bore (19) thereof, said plurality of peripherally spaced tabs (46) being received indexed in said plurality of peripherally spaced slots (48) . 44. A method for sealing a cylinder head joint (11) of an internal combustion engine (10) , the internal combustion engine (10) including a cylinder head (12) having a cylinder head mounting surface, a cylinder block (14) having a cylinder block mounting surface and a cylinder liner (18) mounted in a bore (20) of the cylinder block (14) , the cylinder liner (18) defining a cylinder bore (19) and including a flange (22) extending upwardly from the cylinder block (19) , the method for sealing comprising the steps of: obtaining a spacer plate (24) having a top mounting surface (28) and a bottom mounting surface (30) , said spacer plate (24) including at least one cylinder liner through hole (26) for receiving the cylinder liner (18) therein; placing said spacer plate (24) on the cylinder block (14) with said bottom mounting surface (30) contacting the cylinder block mounting surface and with the cylinder liner (18) received in said at least one cylinder liner through hole (26) ; placing a combustion gas seal (32) in said cylinder liner through hole (26) onto the cylinder liner (18) ; placing the cylinder head (12) on said spacer plate (24) and said combustion gas seal (32) ; and clamping said spacer plate (24) between the cylinder head (12) and the cylinder block (14) and said combustion gas seal (32) between the cylinder head (12) and the cylinder liner (18) . 45. The method of claim 44, wherein the cylinder head (12) and the cylinder liner (18) define a predetermined assembly clearance in said cylinder liner through hole (26) and, in the step of clamping said spacer plate (24) between the cylinder head (12) and the cylinder block (14) and said combustion gas seal (32) between the cylinder head (12) and the cylinder liner (18) , said spacer plate (24) is clamped between the cylinder head (12) and the cylinder block (14) at a first predetermined clamp load and said combustion gas seal (32) is clamped in said predetermined assembly clearance at a second predetermined clamp load selectable independent of said first predetermined clamp load.

Inventors: BOCK ALLYN P, WARD LLOYD A, BOCK, ALLYN, P., WARD, LLOYD, A.
Applicants: CATERPILLAR INC, CATERPILLAR INC.
Application year: 1994
Main classification: F02F11
IPC codes: F02B3, F02F1, F02F11, F16J15